• March 24, 2023
  • Machine Tools
  • Cutting Tools
  • Software
  • Metrology
  • Accessories
  • Mechatronics
  • About us
  • Contact us
  • REGISTER
  • SIGN IN
www.cnctimes.com logo
  • News
  • CT+
  • Webinar
  • Knowledge Center
    • INDUSTRY UPDATES
    • INTERVIEWS
    • VIDEOS
    • TECHNICAL ARTICLES
    • CASE STUDIES
    • PRODUCT SHOWCASE
    • BLOGS
    • SUCCESS STORIES
    • NEWSLETTERS
  • Start Your Subscription
  • Register
  • Sign in

Information

Please login to give the feedback.

Subscription Plans

Subscription Type
Duration
Months
News
Articles
Blogs
Case Studies
Videos
Product Updates
Webinar
Amount
CT
Lifetime
Lifetime
Full Access
Limited Access
Full Access
Limited Access
Limited Access
Limited Access
No Discount
INR 0.00
CT+
6 Months
6 Months
Full Access
Full Access
Full Access
Full Access
Full Access
Full Access
5% Discount
INR 599.00
CT+
Annual
12 Months
Full Access
Full Access
Full Access
Full Access
Full Access
Full Access
10% Discount
INR 999.00

Subscription Plans

Subscription Type
Duration
Months
News
Articles
Blogs
Case Studies
Videos
Product Updates
Webinar
Amount
CT
Lifetime
Lifetime
Full Access
Limited Access
Full Access
Limited Access
Limited Access
Limited Access
No Discount
INR 0.00
CT+
6 Months
6 Months
Full Access
Full Access
Full Access
Full Access
Full Access
Full Access
5% Discount
INR 599.00
CT+
Annual
12 Months
Full Access
Full Access
Full Access
Full Access
Full Access
Full Access
10% Discount
INR 999.00
Successfully registered. Please check your email to activate account.

Registration
  • Sign In



Sorry Captcha Unsuccessful!!

Sign In


OR
If your not registered user first Register
  1. Home
  2. Case Studies
  3. 50% faster turbine blade inspection

50% faster turbine blade inspection

08 April, 2019
  • Tweet
  • share via email
Your comment has been posted.
We have sent you a verification email. To verify, just follow the link in the message.
Some technical error. Please try again.

By Niraj M Wanikar, Chief Editor, CNCTimes.com, 2019-04-08 12:34:00

Checking critical dimensions of complex, high-volume parts can be difficult and time-consuming, particularly when it's necessary to conduct checks on 100% of parts manufactured.

At Europea Microfusioni Aerospaziali – a turbine blade manufacturing company based in Morra De Sanctis near Avellino, Italy, these checks are now performed using Renishaw's PH20 5-axis probe head. Compared to using a 3-axis system, cycle times have been reduced by up to 50%.

Background

Europea Microfusioni Aerospaziali (EMA), is part of the Rolls-Royce Group, a world leader in the manufacturing of propulsion systems for civil and military aircraft, ships, submarines and turbines for industrial energy production.

EMA's Morra De Sanctis facility includes a factory of 20,000 m2 where the company manufactures ultra-high precision stator and rotor blades in special alloys, for high, intermediate and low-pressure stage aeronautical turbines used in both civil and military applications. The company also makes blades for industrial turbines used to generate electricity.

More than two-thirds of EMA's production is for prestigious customers in the aeronautical industry in Italy and around the world, including parent company Rolls-Royce, AgustaWestland, Ansaldo Energia, Avio, Turbocare, Siemens, MAN, and Snecma. Approximately 25% of military aircraft worldwide are fitted with Rolls-Royce engines, many of which use EMA products.

"Since the introduction of the Renishaw PH20 probe head, it's possible to reduce significantly both measurement times and the quantity of stylus changes performed during the control cycle. The use of the MODUS™ software also reduced and optimized programming times. We have managed to reduce cycle times by between 30 and 50% and in some cases even more". Europea Microfusioni Aerospaziali (Italy)

Challenge

Turbine and aero-engine blades are made using super-alloys capable of withstanding very high temperatures and pressures. Their shapes are typically complex, to maximize efficiency and reduce stress and fatigue. And yet, they are made using one of the oldest manufacturing techniques known to mankind: casting.

EMA has perfected a wide range of micro-casting technologies, including those used for the production of blades comprising of single crystals of metal alloy. The company also specializes in the lost wax micro-casting process, which begins with the creation of wax models obtained from metal moulds.

These wax models are then coated with a ceramic material designed to withstand high temperatures. The wax is removed and the ceramic shell forms the mould for the super-alloy. Once solidified and cooled, the cast parts undergo heat treatment and finishing and all components are checked for dimensional accuracy, as well as structural integrity, using ultrasound, X-ray and liquid penetrant testing.

Designing an efficient process for checking the dimensional accuracy of the turbine and aero-engine blades is challenging due to the complex geometry of the part and the requirement to check each and every blade.

Solution

Eng. Vittorio Caggiano, Quality Control Manager: “We had to find a solution that would allow us to improve the efficiency of the dimensional verification process in terms of quantity of parts measured in a unit of time.”

To do so, the company could choose to invest in new measurement machinery, or to reduce the measurement cycle time, thereby increasing the capacity of its existing, in-house measurement machines.

“Up until a couple of years ago, our CMMs operated with PH10 3-axis indexing heads, which set certain limitations both in terms of movement and in stylus changing times.” says Eng. Caggiano. These limitations were due to the complexity of the parts, which demanded many stylus changes for each measurement cycle.

“We worked closely with Renishaw technicians to find a better solution. We also sent our parts to the Renishaw facility in Turin for measurement tests. After these tests, we concluded that the best solution was to invest in new, more flexible and efficient PH20 5-axis probe heads, as well as MODUS metrology software. Renishaw retrofitted the new probes to our existing CMM machines and created fifty measurement programs, written by Renishaw SpA staff on site during our training.”

Results

“The end result is extremely satisfactory,” adds Maurizio Rullo, CMM programmer. “Since the introduction of the Renishaw PH20 probe head, it's possible to reduce significantly both measurement times and the quantity of stylus changes performed during the control cycle. The use of the MODUS software also reduced and optimized programming times. We have managed to reduce cycle times by between 30 and 50% and in some cases even more!”

EMA also invested in a Renishaw Equator™ flexible gauge, which allows the company to check the geometry and shape of high volume parts quickly and efficiently.

“Thanks to the Renishaw Equator, we were able to pool all the checks necessary on certain components, which we previously performed using multiple gauge instruments. As a result, we significantly reduced check times of parts produced in high volumes,” concludes Mr. Rullo.

Renishaw PH20 and MODUS software

PH20's unique ‘head touches' allow measurement points to be taken by moving only the head rather than the CMM structure. Using only the rapid rotary motion of the head, points can be taken faster, and with improved accuracy and repeatability. Furthermore, 5-axis motion eliminates time spent indexing the head.

PH20's infinite positioning capability guarantees optimal feature access, minimising stylus changes. 5-axis simultaneous motion allows larger parts to be measured on the CMM by minimising the space required around the part for head rotation. PH20 automatically aligns itself with the part coordinate system, avoiding stylus collisions and the requirement for accurate fixtures.

The unique ‘inferred calibration' technique developed for PH20 determines the head orientation and probe position in a single operation, allowing subsequent measurement at any head angle.

PH20 is capable of aligning automatically with the work coordinate system: this avoids collisions and eliminates the need for complex fixturing.

The exclusive quick calibration system determines the orientation of the head and probe in a single operation, and makes it possible to take measurements from all angles.

Thanks to the MODUS metrology software, complex measurements and programming measuring cycles have been simplified. The software allows off-line development of advanced programs directly from CAD, with simulation, collision detection and screen-checking functions of the probe path. This makes it possible to minimise machine downtime; the programs reach the machine ready for use and testing times are reduced to a minimum or eliminated altogether.

  • Follow @CNCTimes

Captcha is required.
Sorry Captcha Unsuccessful!!

Latest Case Studies

  • 31 March, 2022

    3D Printing for electric vehicles

  • 29 March, 2022

    British Cycling races ahead with Renishaw additive manufacturing

  • 24 March, 2022

    SolidCAM: Meets the Need for Automation

  • 24 March, 2022

    iMachining: for your speed needs

  • 23 March, 2022

    TOOLTRONIC makes milling-turning centre an all-rounder

  • 21 March, 2022

    Inspection of forged components for shape and dimensional accuracy

  • 10 March, 2022

    eMobility: Measuring technology from ZEISS provides the key for series production

  • 09 March, 2022

    Sanco adapts to CADMOULD for optimizing Injection Molding Process

  • 03 August, 2020

    Automated production line for FFP3 filters up and running after just eleven days with the help of SCHUNK

  • 07 January, 2020

    In-house metrology increases machine tool uptime by 20%

  • 16 December, 2019

    Lifting Devices Provider Cyrus Designs 20% Faster with ZW3D

  • 16 December, 2019

    Khodiyar Industries Chose ZW3D to Speed up Packaging Machine Production

  • 16 December, 2019

    In-house metrology increases machine tool uptime by 20%

  • 19 August, 2019

    Automated workpiece set-up boosts forestry equipment manufacture

  • 30 July, 2019

    Laser interferometer error-proofs linear scale calibration

  • 08 July, 2019

    Improving speed and reducing cost with Renishaw additive manufacturing

  • 04 June, 2019

    Venturing into metal additive manufacturing

  • 13 May, 2019

    Renishaw Equatorâ„¢ gauge enables production growth at major aerospace manufacturer

  • 08 April, 2019

    FARO® QuantumS ScanArm: Executing the Work of Two Measurement Devices

  • 04 April, 2019

    Laser interferometry assures spherical lens quality

  • 01 April, 2019

    Why The World's Third Largest Motorcycle Manufacturer Opted For Universal Robots

Previous Next

Related Case Studies

  • 16 June, 2020

    Equator gauging system leads to 30% increase in manufacturing capacity

    Category: Metrology
  • 12 March, 2019

    BLUM touch probes on Strama-MPS

    Category: Metrology
  • 18 December, 2018

    Measurement of free-form surfaces made easy

    Category: Metrology
  • 14 December, 2018

    A Measuring Tool System That Modified the Concept of Machinery

    Category: Metrology
  • 24 October, 2017

    570,000 individual measurement values per driveshaft

    Category: Metrology
  • 24 October, 2017

    Renishaw technology helps Breton calibrate its in-house machinery and control the quality of its output

    Category: Metrology
  • 24 October, 2017

    Ballbar diagnostics aid airframe manufacture

    Category: Metrology
  • 26 September, 2017

    Making time for Holthinrichs Watches: Renishaw Case Study

    Category: Metrology

TESTIMONIALS VIEW MORE

By Niraj M Wanikar, Chief Editor, CNCTimes.com, 2019-11-19 17:57:22We would like to express our sincere appreciation for your service to us.You have provided us best marketing platform through CNCTime...

Mr.Adil Atar, Ass.Mng.Technical Sales & Service: Precision Machinekraft

By Niraj M Wanikar, Chief Editor, CNCTimes.com, 2016-10-21 09:00:00Dedication and determination is key to success and CNC Times team is evident to it - FARO Business Technologies (I) Pvt Ltd

Ms. Amrita Gokhale , FARO Business Technologies

By Niraj M Wanikar, Chief Editor, CNCTimes.com, 2016-08-25 00:00:00Seminar was really very good, please let us know about future seminars. we would like to attend the seminar on "Machining of the mate...

Roshan Deshmukh, Design Engineer - Ashvini Magnets Private Limited

FOLLOW US

TECHNOLOGY FOCUS

    Machine Tools

    • CNC Lathe
    • Boring Machines
    • Drilling Machines
    • Spark Erosion
    • Wire Cut
    • Vertical Machining Centers - VMC
    • Horizontal Machining Centers - HMC
    • Grinding Machines
    • Gear Cutting Machines
    • Additive Manufacturing - RP
    • Multi-Axis Machines
    • Multi-Tasking Machines
    • Welding Machines
    • Presses
    • Laser Cutting
    • Others
    • IIoT

    Metrology

    • CMM
    • VMM ( Vision Measuring Machines )
    • PCMM ( Portable CMM )
    • Measuring Instruments
    • Probing Technology
    • 3D Scanners
    • Roundness Measurement
    • Surface Roughness Measurement
    • Contour Measuring Machines
    • Others

    Accessories

    • Workholding
    • Toolholders
    • Spindles
    • Coolants
    • Others

    Software

    • CAD
    • CAM
    • CAE
    • ERP
    • Inspection Software
    • Reverse Engineering Software
    • MES
    • Others

    Mechatronics

    • Robotics
    • Automation
    • CNC Controllers
    • Others

    Cutting Tools

    • Turning Tools
    • Milling Tools
    • Grinding Wheels
    • Drilling
    • Others

INDUSTRY VERTICALS

  • General
  • Automotive
  • Aerospace
  • Healthcare
  • Healthcare Engineering
  • FMCG
  • Consumer Durable
  • Defence
  • Electronics
  • Oil & Gas
  • Heritage
  • Heavy Engineering
  • Die & Mold
  • Plastic
  • Footwear
  • Jobshop

PROFILE

  • About us
  • Contact us

Terms of use

  • Privacy Policy
  • Payment Policy
  • Refund Policy
  • Terms and Conditions

Follow us on:

Download CNCTimes App:

Play Store
2023 © www.cnctimes.com  | Payment Policy   |   Terms and Conditions
Developed & Maintained by Deven Infotech